Industrial Blender
Industrial blender is a mixing tools work as fiber blender which is used for combination process of different fibers together intimately to accomplish a desired product characteristic. Industrial blender can influence colouring, strength, softness, absorbency, ease of washing, resistance to wrinkling. The basic function of industrial blender is to give the end-product certain characteristics which are unobtainable from a single fiber component. It is one type of Bale Opener Machine.
Function of Fiber Blender:
Different types of quality of fiber blender, fiber mixing ratio, Optical joint control , air stack , intensive mixing and blending is accomplished by this machine. Fiber blender machine works as fiber mixer in textile industry.
Specifications of Mixing and Blending Machine:
| [label type=”label” title=”Specifications Name“] | [label type=”label” title=”Specifications Value“] |
| Product Category | Spinning |
| Machine Category | Blending Machine |
| Product Name |
Automatic Mixing and Blending Machine |
| Product Model | color blender |
| Product Class | New |
| Origin | China/Others |
| Brand/Manufacturer | According to Manufacturer |
| Agent in Bangladesh | No/Yes |
| Power | 10.2~10.85kw |
| Temperature | Normal |
| Certification | SGS/Others |
| Production Capacity | 800 Kg/h |
| Spinning Method | Ring Spinning |
| Width | 1060mm |
| Beater Diameter | 400mm |
| Beater Type | U Type/ gill pin type |
| Beater No. | 3 pcs, generally 2 U types |
| Gridbar Gauge | 5-12mm |
| Weight | 4500kg |
| Size (LxWxH) | 5066x1600x2746mm |
| Description | The most popular reason for mixing and blending tools is that of combining the properties of two or more drink mixer for fibers. |
Feature of Fabric Blender:
The features of fabric blender are given below –
- The lattices are made up by spiked lattice and feed apron driven by two deceleration motors separately.
- Frequency inverter controls facility of drink mixer where the speed according to production rate
- Electric control system and the spiked lattice motor are driven by frequency inverter to meet different kind of production according to customer needs.
- Fabric blender is used in spinning industry
Disperse dye color development process of industrial blender:
Process definition of industrial blender: A color development process (Lab dip) in which a sample of blended fabric is dyed using industrial blender to mach customer swatch with specification. There are two different laboratory processes that can be used for color development.
Tow bath process: Process for dyeing fabric separately using disperse dye for the poly part and reactive dye for the cotton part.
One bath method: Process for dyeing fabric using a solution that is made by both disperse and reactive dyes together.
Process Requirement: Equipment Used:Mathis padded machine and Mathis drying & curing machine are used for continuous dyeing of 100% cotton and blended fabric.
Key accessories: Weighing machine, pipettes, iron
Safety: While using hazardous chemical the lab personal uses plastic eye gloves, hand gloves and apron.
Color matching for solid dyed blended fabric: Color development by machine, the customers swatch usually happen on the exact type of fabric that customer will be using for bulk production. This information is noted on the lab dip requisite form.But if the exact fabric is not available to ATL lab request for the fabric is to customer through marketing. Customer either may choose to send the fabric to lab which usually delay the color development process or may permit for color developing on available fabric at ATL. In such case color development on the bulk fabric is vary important before going to bulk production. Color development process on the bulk fabric is explained in laboratory general specification.Color reading for the customer swatch for obtaining base recipe or matching of customer swatch to the developed sample can be done in two ways-
Visual matching: For obtaining a base recipe closer to the customer sample laboratory technician look for a similar shade of previous sample fabric from the reference library. The reference library consist of a reference along with varying degrees of shade with an identified variation form the reference sample such as delta equal to 0-1.0 . These sample acts as the calibration reference to the customer swatch.
Instrumental color matching procedure: A base recipe can also be found by scanning the customer swatch in data color. Here follow the detail procedure for measuring sample and obtaining data color recommended recipe specified in lab general specification.
Chemical and condition (for two bath method): Note: For the change of dye supplier above chemical composition can be change.
Process (for two bath method):
The following process is followed in two bath method-
- Dyes and auxiliaries based on the base recipe are weighted using a balance or with an electronic pipette.
- Weighted dyes are mixed with 500 ml of water and stirred for 2 min.
- According to the quality of the fabric padded Mathis is adjusted (usually 60% pick up). Than the sample fabric is set in the machine and dye liquor is poured in for padding.
- The padded sample is put on a frame and than in the Mathis drying and curing machine and then set time and temperature. The sample is dried and takes from the frame.
- A solution of 80% sulfuric acid (H2SO4) is prepared and a piece of approximately (3˝×3˝) is taken from the lab which is soaked into this solution to burn the cotton part and only to keep the poly part. This process is known as skeleton or carbonization. If skeleton does not match against original swatch than start the trial till the shade is matched.
- If the skeleton pieces match with the original swatch than stop the polyester part matching. Before starting the cotton part matching we have to develop at least 5 piece of fabric on the same recipe where the skeleton matched.
- After making the base of polyester part than we start the reduction cleaning (RC) process.
- In this process we want to remove the reserved disperse dye on cotton part with some specification chemicals.
- The lab sample is washed according to the washing condition. Than dried using an iron and checked it to see if it matches with the original sample.
- The cotton dyeing process than start following the 100% cotton Pad-Dry-Curing or pad dry chemical pad steam process. Trial continuous until the sample match perfectly with the cotton part.
Process (for one bath method):
The following process is followed in two bath method-
- Dyes and auxiliaries are mixing and blending based on the base recipe are weighted using a balance or with an electronic pipette.
- Weighted dyes are mixed with 500 ml of water and stirred for 2 min.
- According to the quality of the fabric padded Mathis is adjusted (usually 60% pick up). Than the sample fabric is set in the machine and dye liquor is poured in for padding.
- The padded sample is put on a frame and than in the Mathis drying and curing machine and then set time and temperature. The sample is dried and takes from the frame.
- A solution of 80% sulfuric acid (H2SO4) is prepared and a piece of approximately (3˝×3˝) is taken from the lab which is soaked into this solution to burn the cotton part and only to keep the poly part. This process of mixing and blending is known as skeleton or carbonization. If skeleton does not match against original swatch than start the trial till the shade is matched.
- The lab sample of blended fabric and the pieces of poly part both washed according to the washing condition.
Than the inspection process start for color matching with the customer sample. If the color match perfectly than the color of both part is developed with industrial blender. If not than the recipe is adjusted for both part of dye and trail
[1] Engr Abdur Rahman Swapon, B.Sc. in Textile Engineer, Audust. Email: swapontex@gmail.com
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